2018 Conference

Magnetic Flow Meters

Diagnostics and Smart Meter Verification
Dan Elze
Flow and Density Specialist
Emerson Process Automation

Emerson Confidential
Magnetic Flow Meters
Typical Measurement Points

Emerson Confidential
Magnetic Flow Meter Theory of Operation
Faraday’s Law of Electromagnetic Induction

• A voltage will be induced in a conductor moving in a

magnetic field (E)
• The magnitude of that induced voltage is proportional
– to the velocity of the conductor (V)
– to the length of the conductor (D)
– to the strength of the magnetic field (B)

E=k*B*D*V Michael Faraday (1791 - 1867)

Theory of Operation: Faraday’s Law
Volumetric Flow: Q = V * A
Where: Sensing
Electrodes
Q = Flow rate
V = Velocity E
A = Area
Coils

Faraday’s Law: E=kBDV D B

V
V = E/kBD
Where:
V=Velocity of conductor
k=Proportionality constant
E=Induced voltage
B=Magnetic field strength
D=Length of conductor
Lining
Flange SST Pipe
Magnetic Flow Meter Theory - Faraday’s Law
Variable Flow Rate
Conductive “V” (Feet Per Second)
Volumetric Flow: Q = V * A Process Fluid
Where: SST Tube
Q = Flow rate Lining “D”
V = Velocity Flange
A = Area
Sensing “E”
Electrodes

E=kBDV
“E” Field Coils
k= Proportionality constant
B= Magnetic field Strength
D= Length of conductor
V= Velocity of conductor
E= Induced voltage (linear with velocity)

Magnetic Field “B”

(Constant Strength)
Magnetic Flow Meter Theory
Faraday’s Law and the Flow Rate
• Magmeters calculate fluid velocity (V) by measuring the induced voltage (E) on the electrodes

• Q=V*A
– Volumetric flow rate (Q) is velocity (V) times cross-sectional area (A)

E=k*B*D*V

Not effected by
changes in fluid A
conductivity! v

s
Magnetic Flow Meter Theory
Fluid Conductivity
• Magmeters Require a Conductive Process Fluid
– No Gases
– No Entrapped Air, Foam, or Two-Phase Flow
– Minimum 5 µSiemens/cm
• Conductance is the reciprocal of Resistance and is measured in Siemens (formerly Mhos)
• 10 Siemens = 0.1 Ohm
• 5 µSiemens/cm = 200 kOhm

As we will see in the upcoming slides, diagnostics can help provide inside into process as
well as sensor health, upset conditions, and measurement confidence by measuring things
like electrode resistance, which includes conductivity
Diagnostics Improve Practices

• STANDARD DIAGNOSTICS
– Transmitter Hardware Fault
– Transmitter Software Fault
– Sensor Coil Fault
– Empty Pipe

 DA1 HART DIAGNOSTICS  D01 DIAGNOSTICS (8732E)

– Grounding and Wiring Fault – Grounding and Wiring Fault
– High Process Noise – High Process Noise
– Coated Electrode Detection (8732E)
 D02 DIAGNOSTIC (8732E)
 DA2 HART DIAGNOSTIC – SMART™ Meter Verification
– SMART™ Meter Verification
– Continuous (8732E)
Ground & Wiring Fault Detection Improves Installations
I Would Like To Be Sure my Magmeter is Installed Right The First Time.

It Would Reduce Start-up Time and Cost.

• Improper grounding is a leading cause of flow measurement issues with
ground rings magnetic flow meters
• Rosemount Grounding and Wiring Fault Detection monitors the entire
frequency spectrum to recognize if AC noise is effecting the flow reading –
and alerts you if it is
Magnetic Flow meter Diagnostic Ensures Proper Installation
• Proper grounding is critical to deliver the
best measurement from magnetic
flowmeters

• The magmeter as a built-in spectral

analyzer to ensure no 50 or 60 Hz noise
is present

ground rings
Ground & Wiring Fault Detection Ensures Proper Installation
If excessive voltage is seen at 50 or 60
Hz frequency range, an alert is given to
confirm that wiring has been done
properly
Process Noise Makes Optimization and Maintenance a Tougher Job
I Would Like to Reduce Valve Wear-out, But Also Improve Process Performance.

It Would Reduce Maintenance as well as variability and uncertainty

• Slurries create noisy output resulting in valve actuation – so high levels of damping are common
• Damping = control loop dead-time
• Damping makes the flow signal look stable - but the valve will not change position rapidly - even when
real flow rates change – adding real process variability
• Rosemount High Process Noise Diagnostic and User-selectable Coil Drive provides Maximum Stability
with Minimum Damping
Process Noise
• Caused by disturbance of electrolytic zone around electrodes head
– Exchange of ions between electrode and conductive process fluid
– Measuring a flow signal on the magnitude of several hundred microvolts to a few millivolts

Flow
Electrolytic Zone

+
+ +
+ +
–
– –
– –
Liner
Electrode
Process Noise Profiles
 1/F Noise
 Spike Noise
 White Noise

Different Noise Profiles are Caused by different Process Conditions

Diagnostics can determine which conditions may exist
Drive Frequency and DSP can be used to handle and correct these conditions
Typical Noise Profile (1/F)
 1/F Noise
– Characterized by a frequency spectrum in which the amplitude of the noise decreases with increasing
frequency
– Corner frequency usually less than 10 Hz
– Lower consistency pulp flows, chemical additions
Spike Noise Profile
 Spike Noise
– Characterized by large voltage spikes generated by the impact of solids on the electrode head
– Spikes can be generated at any frequency
– Medium consistency pulp flows, Large Particles

Spikes

Flow Signal
White Noise Profile
 White Noise
– Characterized by essentially constant high noise amplitude
– Noise covers entire frequency range (out to several hundred Hz)
– Medium/High consistency pulp flows, Hydraulic disturbances created by nearby pumps or valves
Flow Optimization
Damping in Noisy Application
Flow PV with No Damping
Control Loop – with Damping
PV (Flow)
FC Add
FE Flow PV with Significant Damping
(Control Valve) Damping
(Flowmeter)

Valve Travel

 Flowmeter (FE)
– Looks Stable, slow to respond to real changes
 Valve (FC)
Process Variability
– Looks stable, slow to control real changes
 Process
– Very Inconsistent, out of control, varying quality
Accept Significant
Process Variability
Process Noise Applications – High Frequency
PV (Flow)

FE FC
(Flowmeter) (Control Valve)

Much higher SNR.

The higher the SNR, the more
stable the signal!

Voltage High Frequency DC

Amplitude Is Stable above Noise

Standard DC
Can’t
overcome
noise

5 Hz 37.5 Hz 50/60 Hz Frequency (Hz)

Frequency
Flow Optimization in Noisy Applications
PV (Flow)
Flow PV with No Damping at 5HZ
FC
FE
(Control Valve)
(Flowmeter)

Move to
37Hz Flow PV with No Damping at 37Hz

Valve Travel

Process Variability
Digital Signal Processing
 As in point 2, value stored. As next
 Spike recorded, but not point stays high, they are added to
included in output average.

 Typical noisy Application  Based on user-entered time-limit,

meter can “jump” to new value or ramp
 Since next point is back in in a more common way
band, point 2 is rejected as
spike noise.
 Process Noise Applications – High Frequency
PV (Flow)

FE FC
(Flowmeter) (Control Valve)

If very high levels of 1/f or white noise is

present, HIGH SIGNAL DC will be required

Voltage
Amplitude

Standard DC
Signal

5 Hz 37.5 Hz 50/60 Hz Frequency (Hz)

Very low Signal to 37 Hz will not address very high

Noise Ratio (SNR) levels of 1/f or white noise
 Process Noise Applications – High Signal DC

Rosemount High-Signal™

Over-powers Noise Like an AC, Delivers

zero stability of a pulsed DC

PV (Flow)
Voltage FC
FE
Amplitude (Flowmeter) (Control Valve)

Standard DC
Signal

5 Hz 37.5 Hz 50/60 Hz Frequency (Hz)

50/60 Hz
Very low Signal to
Noise Ratio (SNR)
Coated Electrode Detection in AMS, Prolink II, or Digital Comm

• 2 levels of electrode coating to set

– Limit 1 – indicates when coating is starting to occur, but has not compromised the flow
measurement
– Limit 2 – coating is now affecting the flow measurement and the meter should be serviced
immediately
– Default Limits 1000 and 3000 kOhm….EVERY PROCESS IS DIFFERENT!
• Best Practices
– Record EC Value with New, Clean, Full sensor
– Record EC Value when coating creates unreliable readings
– Sett Limit 1 based on Maintenance Schedule
SMART Meter Verification Greatly Reduces Calibration Verification Costs
I Would Like to Verify the Magmeter Calibration Without Removing It From The Line Or Using
Extra Equipment .

It Would Reduce Maintenance Time and Cost.

• Verifying mag calibration historically involved removing the
flowmeter from the line or using extra equipment
• Rosemount SMART™ Meter Verification Diagnostic
provides calibration verification without removing the
product from the line or requiring the purchase of extra
equipment
Terminology:
Calibration, Validation, and Verification
• Definition of terms
– Calibration: Establishing the relationship between flow and signal produced by sensor.
– Validation: Confirming flow performance by comparing a primary flow standard to sensor
– Verification: Establishing confidence in performance by analysis of secondary variables
associated with flow
• Frequently these terms are used interchangeably
• Many times calibration or validation is done when only verification is needed
• Emerson baselines an indicating parameter at time of factory calibration that can be
self-checked to perform ongoing verification of the meters calibration and health
– In addition to Electronics Verifications, Rosemount Magmeters use:
• Magnetic field signature (inductance)
• Coil Resistance
• Electrode Resistance

Verification uses a secondary means to show nothing has changed to alter the calibration
Verification tests every part of the entire measurement system
Verification tests against a baseline
Historically Verifying Meters has been time-consuming and forced shutdown

Prover External  Trip to field

Equipment  Technical knowledge and Extra
equipment
 No formal report
 No deviation values
 More than 120 minutes
 May require a process shutdown
Must shutdown,
remove meter
from the line, pay
for proving.
Meter Verification Theory of Operation
• A baseline signature of the magnetic field is taken at the time of factory calibration
– Signature is independent of temperature and flow-rate
– Signature (and calibration) will change if there is a mechanical shift of the coils over time due to vibration,
thermal cycling, etc

A Field Baseline Must Be Performed to Establish Electrode Resistance on the Process

Meter Verification Delivers Pass/Fail for Calibration and Health
Established at factory calibration Measured in the field
8714i Meter Verification
• Compares measured coil
signature to baseline coil Sensor
Signature 8714i
Pass/F
Baseline Measure Deviation Criteria
signature Parameter
Values Values
ail

• % deviation is calculated Coil Signature 19.5 19.6

• User assigns acceptance Coil
criteria based on application Resistance
15.2 15.6

• Verifies the health of coil and Electrode

260.7 245.6
Resistance
electrode circuits
Signature 8714i
Sensor Pass/F
Baseline Measure Deviation Criteria
Parameter ail
Values Values

Coil Signature 19.5 19.6 0.51% 1% Pass

Coil Resistance 15.2 15.6 Range Pass

Electrode
260.7 245.6 Range Pass
Resistance
Meter Verification Offering Provides Options for Documentation

Report from AMS Manual Verification Report

Available in Reference Manual or Rosemount.com

Prolink III Report

Continuous SMART Meter Verification is always running

Continuous Meter Verification and Analog

Loop Verification can be found here
Diagnostics Matter: Proven Results
The SMART™ Meter Verification diagnostic enabled this
wastewater treatment plant to reduce their chemical
usage and improve throughput.
• Waste activated sludge
• Meter verification required for this flow point in order to
verify that biological activity was kept at correct levels
• SMART™ Meter Verification allowed this plant to
extend time between meter removal increasing the
process efficiency and reducing maintenance costs
• 00830-1200-4727
Universal™ Capabilities Extend Diagnostics to any Mag Installation
I would like to have diagnostic capabilities on my old installed base of magnetic flowmeters.

It would allow me to optimize my processes without requiring replacement of perfectly good

sensors.

• Replacement of an existing installed base is

expensive and impractical, especially when the
sensor is still healthy
 Diagnostics not only work on Rosemount sensors
they work on other manufacturers’ sensors as well
Rosemount Mag
Universal Diagnostic™ Technology
• Universal Capabilities
– Only Rosemount offers the functionality to drive tubes across a wide-
ranging currents
• Scalable from 0.075 to 0.5 amps
– Can drive virtually any flow tube sensor from any manufacturers
• Simple conversion of others k-factors to Rosemount calibration
numbers
– Diagnostics not only work on Rosemount flow tube sensors –
they work on other manufacturers’ sensors as well.
Universal Meter Verification improves installations with other manufacturers’ sensors
Typical Meter Verification Capabilities of other Manufacturers

 Trip to field
 Technical knowledge and Extra equipment
 No formal report
 No deviation values
 More than 120 minutes

Rosemount Universal  No Trip to field

 No Extra equipment, simple meter
verification diagnostic
 Formal report
 Deviation values
 Approx 6 minutes
Universal Transmitters
- How do I make it work?

Making Universal Work is as easy as 1 - 2 - 3….

1. Review the application
– Verify sensor is in working condition and will work with the Universal transmitter
2. Connect the Universal transmitter to the sensor
– Wiring diagrams are provided in the reference manual
3. Determine the Universal Calibration Number
– Calibration Number Prediction
– Universal Auto Trim
– Flow lab calibration
FAQ Documents:
Determining Universal Calibration Numbers
• Universal calibration number calculation tool
– Excel spreadsheet that converts sensor K-Factor to a Rosemount 16-digit calibration number
– Available for:
• Foxboro 2800
• Krohne Optiflux 4000 and IFS 4000
• Yokogawa Admag and Admag AXF
• Universal Auto-trim
– Calibrates Universal transmitter to current flow reading
– Requires a known flow rate
– Best option when replacing a transmitter to get access to
diagnostics
• Simplifies In-Situ Calibration
• Send sensor to Rosemount for calibration
– Can be supported, but not typically done as it requires removal of the sensor
Universal Matters: Proven Results
Universal transmitter capabilities allowed this municipal
treatment facility to improve quality and reduce
maintenance costs
• Raw feed water
• Installed flow meter was giving an erratic output
• 30-inch sensor which could not be removed from
process without shutting down the facility
• Universal transmitter capabilities allowed this user to
continue operation and provided a stable output
allowing the facility move to automatic control of
chemical feeds
• 00830-0900-4727
What’s NEW? Sensor and Transmitter Migration from ES to EM
• Originally driven by new requirements for FM approval, but drove project to make other
enhancements.
• Additional Diagnotstics 3-Build Paint System
Standard Process Meter Health •3-build paint system
Configurable Grounding / Wiring Transmitter – Base layer conversion coating improves material adhesion and
Empty Pipe Verification prevents corrosive spread
Coil Short High Process Noise Coil Circuit Health – Thick build epoxy mid-coat provides primary resistance to corrosion
Electrode Short Electrode Coating Electrode Circuit – Polyurethane top-coat provides UV and corrosion resistance
Detection Health
Coil Over Current Sensor
• Surpasses NEMA 4X Testing
Verification – Passed testing when subjected to 1500 hours of salt spray
Electrode Continuous Smart
Saturation Meter Verification
Electronics Failure

• Improved LOI Design Field Replaceable Terminal Block (on some models)

Emerson Confidential 39
What does this change mean for you?
• Additional Diagnostic Features
• Enhancements to 8712 wall mount to match 8732 features
• MODEL CODES will be slightly different
– Besides EM vs ES, the agency approval section of the model code may change
• When ordering parts or mixing platforms between sensor and transmitter, check with your local
sales representative
8712ES 8712EM

Emerson Confidential 40
For more information visit Midwest Municipal Instrumentation

Booths 1105-1106

Emerson Confidential 41
Thank You
Any Questions?

Emerson Confidential